Butt splicer



C. V. ALLEN Dec. 15, 1964 BUTT SPLICER 3 Sheets-Sheet 1 Filed Oct 18, 1962 INVENTOR.

CLAUDE v ALLEN ATTORNEYS.

C- V. ALLEN Dec. 15, 1964 BUTT SPLICER 3 Sheets-Sheet 2 Filed Oct. 18, 1962 wvEmm INVENTOR.

CLAUDE V ALLEN ATTORNEYS.

Dec. 15, 1964 c. v. ALLEN 3,161,368

BUTT SPLICER Filed Oct. 18, 1962 I s Sheets-Sheet s I NVENTOR. CLAUDE V. AJ,LEN

ATTORNEYS! United States Patent 3,1513% Patented Dec. 15, 1964 3,161,368 BUTT SYLllCER Claude V. Allen, Newhurgh, N31,, assignor to The inta- Roto Machine Company, Inc., Richmond, Va., a corporation of Virginia Filed Oct. 18, 1962, Ser. No. 231,373 Claims. (Cl. 242-534) This invention relates generally to new and useful improvements in web feeding machines, and more particularly to improvements in machines which automatically butt splice the lead end of a fresh roll of paperboard to the trailing end of a previously used roll of paperboard to supply continuous web under constant tension from the splicing stations to a subsequent operation performing machine.

In the production of paperboard containers, such as milk and other food cartons, a web is withdrawn from a supply roll and fed into printing, punching and other operations performing machines to fabricate the individual container blanks in printed and cutout form. Presently machines for performing these functions operate at a web speed of approximately 300 feet per minute and, accordingly, the time lost in transferring supply rolls of paperboard becomes substantial when the machinery must be stopped to manually splice a new supply roll to an old one. Butt splicers are in existence which perform the splice automatically, cutting the old roll and splicing the lead end of the new roll in butt fashion to the cut end of the web without reducing the speed of the machine. At the time the splice is performed, a considerable change in web tension takes place since the torque on the old roll is very small while the torque of the new roll, which may be as much as 60 or 72 inches in diameter, is very high. The sudden change in web tension of high magnitude imposed by the change in rolls makes it diiiicult to properly perform the splice at high speed without introducing speed changes to the web as a result of the change in web tension and without the possibility of web breakage or other damage. Therefore, existing equipment has been provided with complex mechanism for introducing considerable slack, or loops, in the web so that the tension may be increased gradually at the draw end of the web, or otherwise provided with special shock and dancer rolls in an attempt to offset the changes in web tension and the resultant changes in web speed.

It is a primary object of the present invention to provide an improved apparatus for feeding a web between a supply roll and an advancing means wherein means is provided for maintaining constant web tension in spite of the changing size of the supply roll.

it is another object of this invention to provide a machine of the character stated, and capable of maintaining constant web tension which is simple in design, rugged in construction and economical to manufacture.

It is a further object of this invention to provide improved apparatus, of the above described characteristics,

wherein the improvement embodies an accumulator roll positioned between the supply roll and the advancing means and over which the web is trained, the accumulator roll being supported for reciprocal movement in a path longitudinally of the web, and increased Web tension causmg movement of such accumulator roll in a direction opposed by fiuid pressure means tending to move the roll A further object of the invention is to provide improved apparatus of the above stated characteristics wherein the control means embodies differential gearing operatively connected to the accumulator roll and operative through a lever means to adjust the fluid pressure means and the pressure on the supply roll brake simultaneously, the pressure on the former increasing while the pressure on the latter decreases.

Still another object of the invention is to provide improved apparatus of the above described characteristics wherein said control means includes means for adjusting the initial pressure settin s of said fluid pressure means, and means for varying the control effected by moving the pivot axis of the said lever.

A further object of the invention is to provide improved apparatus, of the above stated characteristics, in combination with a butt splicer and a pair of supply rolls, said accumulator and associated rolls and associated elements permitting the maintaining of a substantially constant web pressure before, during and after a splice is being made between a new and an old web without stopping the advance of the web being spliced and in spite of the Variations in resistance to web feed as the old supply roll diminishes and when the feed is changed to the new supply roll having much higher inertia.

Still another object of the invention is to provide an improved butt splicing machine, of the above described characteristics, wherein said accumulator roll and associated control device regulates the brake pressure on the new roll to be at a minimum when the splice is made.

The novel features that are considered characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and its method of operation, together with additional objects and advantages thereof, will best be understood from the following description of a specific embodiment when read in connection with the accompanying drawing, wherein like reference characters indicate like parts throughout the several figures and in which:

FIG. 1 is an elevation of a butt spllcer machine constructed in accordance with the present invention, and partially broken away to reveal internal details;

PEG. 2 is an enlarged sectional view taken from line 22 of FIG. 1 and looking in the direction of the arrows;

FIG. 3 is a sectional view taken from line 33 of FIG. 2 looking in the direction of the arrows;

FIG. 4 is an enlarged fragmentary elevation, partly broken away, of the air pressure regulator control mechanism;

FIG. 5 is a section taken along line 5-5 of FIG. 4 and looking in the direction of the arrows, and

FIG. 6 is a schematic diagram of the fluid pressure circuit of the regulator control mechanism. 7

Referring now more particularly to the drawings, there is shown in FIG. 1 a butt splicer machine iii, of more or less conventional construction, to which has been added the improvement comprising an accumulator roll 12 and accessory apparatus for regulating the tension of the web before, during and after the splice has been made, and in spite of the condition of the supply roll. Machine 10 comprises a frame having a pair of side walls 14, only one of which is shown, and which support and mount the splicing apparatus. A paperboard supply roll is shown diagrammatically at 16 having a core or spindle 18 from which the paper web 2t? is constantly fed into and through the butt splicer at a high rate of speed, approximately 300 feet per minute.

The web is passed between a pair of normally stationary cutter rolls 22, to and between a pair of normally stationary splicing rolls 24, under an idler roll 26, under the accumulator roll 12, and between the draw rolls 2S and 7 described.

V with respect to the fixed rack 54 by reason of 3 30 to another idler roll 32. From thence the paper web may be fed over additional rolls such as dancer and shock rolls to further machines which process the paper by printing, punchingor similar operations.

The supply roll 16 is shown as having diminished to a point Where virtually only the core 18 remains. A second, or new supply roll 34 on core or spindle 35, has a paper web 36 diagrammatically shownwith its leading end attached to one of the stationary cutter rolls 22.

The pull rolls 28, are driven by conventional equipment at the speed indicated above to draw the web 20, or 36, through the butt splicer in its passage to the machines which perform the latter and successive operations. The

cutter and splicer rolls 22, 24'are operated by conven- Conventional apparatus for performing this operation is well known and need not be described here. Examples of such apparatus are fully set forth in Patent No. 2,706,515 granted to A. I. Evers on April 19, 1955, and in Patent No. 2,745,464 granted to Auerbacher et al. on May 15, 1956.

'The accumulator roll 12 and its accessory apparatus, forming the present improvement in the butt splicer, is best described with reference to FIGS. 1, 2 and 3. This roll performs the function of providing a loop or slack in the web 20 which is partially taken up during the" period of time that the splice is actually performed, and also insures the. maintenance of a substantiallyconstant web tension before, during and after the splice and regardless of the amount of paper web remaining on the new or old supply roll. To this end, the accumulator roll 12 comprises a cylinder closed at each end by a wall 38, only; one

of which is shown in FIG. 2. The cylinder axle 40 isv mounted in a sealed bearing 42 so that roll 12 may turn with respect to the'axle 40 as the web is pulled through the rolls 28 and 30.

Roll 12 is supported for reciprocal movement in a path longitudinally of the web by means 7 v of a bearing 44, at each end of the axle 40, which slides in a space 46 providedbetween upper and lower track secured to the frame sides 14 in any suitable manner,

and at least one pair of track. members is recessed outwardly of the space 46-to provide alongitudinally extending space 52 in which are housed the parts to be In space 52 is mounted on elongated fixed rack 54 having upwardly extending gear teeth. Lower track member is provided with a deepened recess 56, adjacent the rack 54, in whichis slidably-mounted a second elongated rack 58. Axle 40 of the accumulatorroll has a reduced diameter end which extends into space 52, and a pair of in their positions corresponding to such extended position of the roll. As the accumulator roll 12 moves to the right in FIG. 2, the'racks 58 and its extension 68 together with pivot 70 on levers 72 and 74 will move to the left.

Intermediate or substantially central, balanced positions of these latter, parts are shown in broken lines in FIGS. 2. Further movement of roll 12 to a position beyond its fully retracted position shownin broken lines in FIG. 1 is adapted to actuate a limit switch 130 by abutment of the end of the rack extension, or one or both. levers 72, 74, with a roller 132 whichcontrols the switch. As a safety precaution, switch 130 is connected ina manner not illustrated to turn off the power drive to draw rolls 28, 30 and stop the web when the web tension becomes so great as to tend to move the accumulator roll beyond fully retracted position. At eachend of the roll 12, the bearing 44 of axle 40 is screw coupled at 75 to a rod 79 which is connected at its opposite end to the piston of afiuidpressure cylinder fixed to frame 14. Fluid pressure within the cylinder 80 is adapted to move the pistons to the left carrying the roll 12in the same direction against the force of the tension in web 20 or 36. Afixed rack 54 and pinion 62 on shaft 40 is preferably provided on each end of the accumulator roll 12, FIG. 6, but the differentially geared rack, or movable, rack 58 and its associated pinion 64 may be omitted-on one side of the accumulator roll. If desired, for control of additional apparatus, the movable rack and associatedequipment may be suppliedon the second side as well as on the first. I 1 Referring particularly to'FIGS. 2,- 4 and 5, the control apparatus associated with the accumulator roll will now 'be described. A C -shaped channel, or bracket,.member 76 is clamped to the outer surface of frame wall 14 at one edgether'eof by means of bolts passing through up- Wardly and downwardly directed extension flanges 78 and 80 on the bracket member. Rotatably mounted in the bracket 76 are a pair of vertically spaced manipulating wheels or knobs 82 carrying screws 84 extending inwardly toward the frame wall 14. Threaded on the screws 84 are a pairof lugs 86 to which are bolted support members 88 each carrying a pin 90, or 92.

One end of each pin is engaged in a slot 94, or 96 respectively, formedlongitudinallyin the levers 72 and 74. Thus, longitudinal movement of the rack 58 and its extension 68 is adapted to move the inner end of the levers 72 and 74 and cause them to turn about the pivots and 92, respectively. Manipulation of either" wheel 82 serves to move the pivot connected therewith inits respective slot longitudinally of the lever, so that the pivot for each lever may be adjusted'at will tochange the length 7 of arc moved ,by theouter end of the lever for a come substantially equal diameter pinions 62' and 64 are fixed;

to the axle portion 60 by a key 66 and are respectively in mesh with theracks 54 and 58. To provide a differential between the racks and pinions, preferably the racks and pinions have teeth of the same pitch but the pinion 64 has a least one more tooth than the pinion 62.- Accordingly, if the accumulator roll is moved linearly to connected by a pivot 70 to a pair of levers 72 and'. 74,-

see FIGS. 2 and 5. In FIGS. 1 and 2, the accumulator roll is illustrated in its most extended position and the racks 54 and 58 and levers 72, 74. are shown in full line sponding unit of lineal distance moved by its inner end. A mounting plate 98 is suitably secured to the outside surface of frame wall 14 and is provided with a pair of slots 100 through which the levers 72 and 74 extend with sufficient play to permit theirturning movement. To the support plate. 98 are'attached a pair of grooved track members 102 on opposite sides of the slots 100. Slidably mounted for fixed and adjusted support in these tracks are the bases of a pair of L-shaped bracket members 104 supporting a pair of similar fluid pressure regulators 106 and 10 8. These regulators have actuating pins 110 and 112 engaged by levers 74 and 72 respectively. When an air pressure system is used as illustrated,.the regulators may in air pressure regulators such as marketed under the trade named, Norgren No. 20 AG-X266...

Toinitially adjust, the air pressure for which the regulators 106 and 108 are set, there are provided brackets and 107 rotatably mounting manipulatable heads 114 which vcarry'movable screws 116 threadedfor movement in the blocks 109, fixed to the regulatorsupport brackets 104; Since the brackets 105 and 107 are fixed to the plate a 98, turning of the knobs 114 will threadedly'move the 106.

support b1ocks'104 to initially position the regulators and 108 in any desired positions with respect to the levers 72 and 74 which they engage.

A fluid pressure system utilizing air pressure is diagrammatically shown in FIG. 6. The main source of air is connected by a line 118 to both air pressure cylinders through a manually operable three-way cock 120 and a booster valve 122. A meter 111 is provided in the line to indicate the air pressure at the cylinders. The manual three-way cock 120 may be one of standard con struction, such as a Crane #268, and enables shutting down the line to the cylinders 80 for maintenance purposes. The booster valve 122 permits a quick reversal of air flow under actuation of the air pressure regulator 108, and this valve may be of a standard booster type such as is marketed under the trade name Governair No. 4513.

A branch air pressure line 123 leads from the main source for air through a booster valve 122' to a pair of brakes 124 and 126 through three-way cocks 120. The brakes 124 and 126 are arranged to apply pressure to the spindles 18 and on the old and new supply rolls, respectively. The valve 122' and cocks 120' may be identical to the valve 122 and cock 120.

The mode of operation of the above described accumulator roll and its accessory control apparatus will now be apparent. Referring particularly to FIGS. 2 and 6, an increased web tension will cause the accumulator roll 12 to move to the right against the air pressure in cylinders 80. This will cause the inner ends of the levers 72 and 74 to move to the left through the medium of the difierential gearing and racks 54, 58. The levers pivot about the pins 90 and 92 permitting the outwardly biased actuating member 110, on regulator 106, to follow lever 74 and move to the right. The corresponding actuating member 112, on regulator 108 also is moved to the right by lever 72 or inwardly of regulator 108.

Accordingly, the pressure regulators 106 and 108 being opposed and connected respectively to the brakes on the supply rolls and to the air pressure cylinders 80 will decrease the brake pressures at 124 and 126 and increase the pressures in cylinders 80. Therefore, the movement of the accumulator roll 12 to the right is in opposition to the resulting increased pressure of the cylinders 80 which tends to retain it in its original position and oppose movement therefrom.

Thus, increased web tension tending to move the accumulator roll toward the right or retracted position as shown at its extreme in broken lines in FIG. 1, causes an increase in pressure on the cylinder tending to return the accumulator roll and at the same time, lowers the pressure of the brake on the supply roll whether it be the new roll or the old roll which, of course, reduces the web tension and permits the higher pressure in the cylinders 80 to return the roll toward a normal, balance position.

A lowering of the web tension, however caused, enables the cylinders 80 to push the roll 12 to the left from its normal balance position, thus taking up slack in the web and moving the slide rack 58 to the right. This, of course, turns the levers 72, 74 clockwise about pivots 90, 92 or in the opposite direction to that described above for counterclockwise movement of the levers. Such direction of lever movement causes the regulators 106 and 103 to increase the brake pressures and decrease the cylinder pressures so that again the accumulator roll will be returned to its normal, balanced position and maintain stability of control.

To initially set the control apparatus, assuming a web inches wide with a tension of 10 pounds per lineal inch and using a 6 inch core on the supply rolls with a maximum diameter supply roll of 60 inches when new or fresh, the torque required to brake the roll under consideration during the unwind when the Web material has approached the core would be 40 l0 lbs. per lineal inch or 400 pounds total tension multiplied by the 3 inch radius of the core, or 1200 inch pounds. The torque required on a brake for the maximum diameter or new roll would be 400 pounds total tension 30 inch radius for the 60 inch supply roll or a total of 12,000 inch pounds. The tension on the web both approaching and departing from the accumulator roll 12 would be 400 pounds. Consequently, a force of 800 pounds on the accumulator cylinders would be required toexactly balance the web tension.

Under these conditions, the accumulator roll pressure at cylinders 80 is set to equal approximately 775 pounds of force by adjustment of position of regulator 108 when the accumulator roll is completely extended, the full line position shown in FIG. 2. In this position, the pressure at brakes 124 and 126 is set to equal 12,000 inch pounds of torque by adjustment of the position of regulator 106, because this will be required on a new roll. The accumulator roll would then be set back to the center or balanced position with the levers and accessories as shown in broken lines in FIG. 2, and a pressure reading of 800 pounds would be set at the cylinders using the manipulating wheels 114 to adjust the pressure regulator 108 so that during normal running conditions the accumulator roll would be in this position to exactly balance the web tension.

The brake pressure would be set for 1200 inch pounds of torque by regulator 106 when the roll 12 is in this center, or balanced, position. The accumulator roll would then be completely retracted to the broken line position, FIG. 1, and the cylinder pressure would be set for approximately 825 pounds, while the brake pressure is adjusted to go to zero. In making these initial settings it may be necessary to adjust the positions of pins and 92 by manipulation of wheels 82. When initially set up in this manner, the accumulator roll will ride in the center position as long as the 10 pounds per lineal inch tension in the web is maintained. Any increase in web tension which would normally take place if the brake did not change and the unwinding roll becomes smaller will retract the accumulator roll, lower the brake pressure and cause the tension in the web to decrease allowing the accumulator roll to go back to its center, or balance position.

Thus, one of the outstanding features of the invention is the fact that the brake on the new roll is at its minimum pressure when the splice is made. This follows because as a diminishing roll gets smaller its torque requirement becomes less, but if the brake pressure did not change, the accumulator roll would be retracted due to the increase in web tension. As soon as such increase takes place, the accumulator roll by moving into the retracted position automatically decreases the pressure on the brake of the diminishing roll which in turn allows the accumulator roll to go forward again.

The controls are so set that when the diminishing roll is close to the core the accumulator roll is in the center position. In this position there is a minimum of pressure applied to the brake and when a splice is made, since this identical pressure is applied to the brake on the full roll, the full roll starts otf with hardly any resistance. Due to the sudden increase in diameter from that of the core of the old roll to that of the full new supply roll, the tension in the web increases which immediately pulls the accumulator roll back toward its full retracted position. This increases the pressure applied to the accumulator cylinders to cause the roll to extend and apply the proper, needed pressure to the brake of the full roll.

It is apparent from the above that the accumulator roll above described has the important advantage of holding web storage before and after the splice which is released during the splice and also controls the brake pressure on the supply rolls. The improved structure accordingly permits the maintenance of constant web tension before, during and after the splice and regardless of the size of the supply roll. While the invention has been described as applied to a butt splicer, it is apparent that it may be used with other web moving apparatus and will accomplish the function of maintaining a constant web tension between a supply roll and a drawroll regardless of the change of size of the supply roll. 7

Although a certain specific embodiment ofthe invention has been shown and described, it is obvious that many modifications thereof are possible. The invention, therefore, is not to be restricted except insofar as is necessitated by the prior art and 'by the spirit of the f appended claims.

What is claimed is: a 1. Apparatus for butt splicing moving Webs of paperboard or the like, comprising in combination a pair of supply rolls each having a fluid pressure brake,'means for a continuously advancing a web from one of said supply rolls, splicing means for advancing the lead end of a new web from the other of said supply rolls, severing said lead end and the old web and automatically securing a butt joint between the new and old Webs as said Webs are being continuously advanced, and means responsive to Web tension to simultaneously adjust the brake pressures on both said supply rolls and maintain substantially constant web tension, said last named means comprising an accumulator roll supported for substantial reciprocal movements and over which a spliced web is trained to form a loop, a fluid pressure cylinder device connected to said accumulator roll so that pressure in the cylinder device opposes movement of the accumulator roll in the direction caused by increased web tension in said loop,

a source of pressure fluid connected to said cylinder device and to said brakes, and pressure fluid control means mechanically connected to and responsive to movements of said accumulator roll and'soarranged as to simultan- I I eously increase the pressure in said cylinder device and in said cylinder device-andincrease the pressure of both said brakes When the web tension decreases 2. Butt splicing apparatus according'to claim 1 wherein said pressure fluid control means comprises at least one lever mounted ,for turning movement about a pivot, and a pair of pressure regulators connected to modify the fluid pressure supplied to said brakes and said cylinder device respectively, said lever being arranged to control a said regulators upon turning movement in either direction.

3. Butt splicing apparatus according to claim 2 wherein said lever is provided with a longitudinal slot, a movable pin positioned in said slot for acting as an adjustable lever pivot to vary the control exercised by movements of said lever on said regulators.

' 4. Butt splicing apparatusraccording to claim 2 Wherein said pair of pressure regulators are movably mounted for adjustment with respect to said lever whereby to other pinion, and said slidable rack being connected to said lever to turn the same.

decrease the pressure, of both said brakes when the web tension increases and simultaneously reduce the pressure References Cited in'the file of this patent UNITED STATES PATENTS Dickhaut Mar. 27, 1934 3,043,535 Chittenden July 10, 1962 3,083,602 Obenshain Apr. 2, 1963 

1. APPARATUS FOR BUTT SPLICING MOVING WEBS OF PAPERBOARD OR THE LIKE, COMPRISING IN COMBINATION A PAIR OF SUPPLY ROLLS EACH HAVING A FLUID PRESSURE BRAKE, MEANS FOR CONTINUOUSLY ADVANCING A WEB FROM ONE OF SAID SUPPLY ROLLS, SPLICING MEANS FOR ADVANCING THE LEAD END OF A NEW WEB FROM THE OTHER OF SAID SUPPLY ROLLS, SEVERING SAID LEAD END AND THE OLD WEB AND AUTOMATICALLY SECURING A BUTT JOINT BETWEEN THE NEW AND OLD WEBS AS SAID WEBS ARE BEING CONTINUOUSLY ADVANCED, AND MEANS RESPONSIVE TO WEB TENSION TO SIMULTANEOUSLY ADJUST THE BRAKE PRESSURES ON BOTH SAID SUPPLY ROLLS AND MAINTAIN SUBSTANTIALLY CONSTANT WEB TENSION, SAID LAST NAMED MEANS COMPRISING AN ACCUMULATOR ROLL SUPPORTED FOR SUBSTANTIAL RECIPROCAL MOVEMENTS AND OVER WHICH A SPLICED WEB IS TRAINED TO FORM A LOOP, A FLUID PRESSURE CYLINDER DEVICE CONNECTED TO SAID ACCUMULATOR ROLL SO THAT PRESSURE IN THE CYLINDER DEVICE OPPOSES MOVEMENT OF THE ACCUMULATOR ROLL IN THE DIRECTION CAUSED BY INCREASED WEB TENSION IN SAID LOOP, A SOURCE OF PRESSURE FLUID CONNECTED TO SAID CYLINDER DEVICE AND TO SAID BRAKES, AND PRESSURE FLUID CONTROL MEANS MECHANICALLY CONNECTED TO AND RESPONSIVE TO MOVEMENTS OF SAID ACCUMULATOR ROLL AND SO ARRANGED AS TO SIMULTANEOUSLY INCREASE THE PRESSURE IN SAID CYLINDER DEVICE AND DECREASE THE PRESSURE OF BOTH SAID BRAKES WHEN THE WEB TENSION INCREASES AND SIMULTANEOUSLY REDUCE THE PRESSURE IN SAID CYLINDER DEVICE AND INCREASE THE PRESSURE OF BOTH SAID BRAKES WHEN THE WEB TENSION DECREASES. 